Kohler 3.5EFOZ User manual

Marine Generator Sets

TP-6138 5/02

Service Parts

Models:

3.5EFOZ/4EOZ

Table of Contents

Introduction 1.................................................................

Numbering System Significance 1...............................................

Illustrations 1..................................................................

How to Find Part Numbers 1....................................................

Hardware References 1........................................................

Specification Number Index 2...................................................

Group 1: Crankcase 3.........................................................

Group 2: Crankshaft and Piston 4...............................................

Group 3: Cylinder Head 6......................................................

Group 4: Gear Timing and Cover 8..............................................

Group 5: Speed Control Shaft 10................................................

Group 6: Fuel Lines 11.........................................................

Group 7: Flywheel 12..........................................................

Group 8: Starter Motor 13......................................................

Group 9: Exhaust System 14...................................................

Group 10: Oil Cooler and Lines 15...............................................

Group 11: Seawater Pump 16...................................................

Group 12: Oil Draining Lines 17.................................................

Group 13: Fuel Filter and Pump 18..............................................

Group 14: Air Intake Filter 19...................................................

Group 15: Gasket Set 20.......................................................

Group 16: Base and Mounting 22...............................................

Group 17: Sound Shield 24.....................................................

Group 18: Generator and Mounting 26...........................................

Group 19: Controller and Mounting 28...........................................

Group 20: Control Panel 30.....................................................

Group 21: Siphon Break and Lines 31............................................

Group 22: Literature 32........................................................

Paint and Miscellaneous Parts 32................................................

Accessories 32................................................................

Appendix A Abbreviations A-1..................................................

Appendix B Common Hardware Application Guidelines A-3.........................

Appendix C General Torque Specifications A-4....................................

Appendix D Common Hardware Identification A-5.................................

Appendix E Common Hardware List A-6.........................................

1

TP-6138 5/02

Introduction

This manual lists service replacement parts for 4 kW

generator sets.

At the time of print this manual applied to the generator

set specification (spec) numbers listed in the

Specification Number Index. On occasion this manual

may apply to specs not listed in the Specification

Number Index.

Information in this publication represents data available

at the time of print. Kohler Co. reserves the right to

change this publication and the products represented

without notice and without any obligation or liability

whatsoever.

This manual includes the following main sections:

Table of Contents. Lists the sections of the manual.

Introduction (and other information sections).

Contains introductory material about part numbers,

illustrations, and hardware.

Specification Number Index. Lists the generator set

specs and groups.

Group Parts Lists. List the part numbers of parts in the

groups.

Kit Sections. List modules and accessories and their

parts.

Appendices. Include Abbreviations, Common

Hardware Application Guidelines, General Torque

Specifications, Common Hardware Identification, and

Common Hardware List.

x:in:004:002

Numbering System Significance

This manual uses the following numbering systems:

Specification Number. The product identification

number located on the generator set nameplate.

Specification numbers break down into groups.

Group Number. A unique number representing a parts

group needed to assemble a generator set function. For

example, Group 101 is the Air Intake group.

Variation or Module Number. A group might have

several variations. Each variation performs the same

function with different parts lists. For example, a 50 Hz

generator alternator and a 60 Hz generator alternator

both perform the same function; however, with different

parts. Each difference requires a group variation or

module number.

Part Number. The part number identifies an individual

assembly, subassembly, component, or accessory kit.

x:in:004:003:a

Illustrations

Illustrations (or exploded-view drawings) best

representing the widest range of variations accompany

most groups in this manual. Illustrations do not depict all

details and may not show all parts. Do not use

illustrations for assembly or disassembly.

x:in:004:004:a

How to Find Part Numbers

Use the following steps to locate a service replacement

part.

1. Locate the generator set nameplate to identify the

generator set spec number.

2. Locate a second generator set nameplate listing

accessories to identify installed modules.On

some models the accessory nameplate is mounted

inside the generator junction box.

3. Turn to the Specification Number Index.The

first column lists the generator set spec numbers.

The headings identify the groups of parts that make

up the generator set.

4. Identify the group most likely to include the

service part number.

5. Find the group variation number at the

intersection of the spec number row and the group

column. Note the variation number.

6. Page forward to locate the group identified in

step 4 or find the appropriate page in the Table of

Contents.

7. Find the part on the illustration and note the item

number of the part or find the part description in

the parts list.

8. Select the part number that corresponds to

your group variation. The first column lists the

illustration item number. Find the variation

identified in the Specification Number Index or the

module number found on the generator set

nameplate in the appropriate column on the right

side of the parts list table. Find the quantity used at

the intersection of the item number row and the

variation column. A blank space at the intersection

means the variation/module does not use that part

number.

x:in:004:005

Hardware References

Many common hardware items do not appear in parts

manuals or will appear as common hardware entries. A

common hardware entry lists the size of the hardware.

For example, an item that appears as “Hardware,

3/8-16” in the text means that the piece is 3/8-16 size.

Obtain common hardware locally or, if contacting the

factory, use the Common Hardware List in the appendix

to identify the common hardware part number and

specifications. See Common Hardware Application

Guidelines in the appendix for mating hardware

instructions.

Some hardware items require a specific size or some

other characteristic. In that case, use the part number

listedinthetext.

When replacing hardware, do not substitute inferior

grade hardware. Replacement hardware grade should

be equal to or better than the grade of the

manufacturer’s original hardware. Use the Common

Hardware List in the appendix to identify the common

hardware hardness.

x:in:004:006

2

TP-6138 5/02

Specification Number Index

Group No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Spec. No.

VARIATION NUMBER

Group Title

3.5EFOZ

GM20642-SA1 1 2 1 1 1 1 1 1 1 1 1 1 1

4EOZ

GM20641-SA1 1 1 1 1 1 1 1 1 1 1 1 1 1

GroupNo. 141516171819202122

Spec No.

VARIATION NUMBER

Group Title

3.5EFOZ

GM20642-SA1 1 1 1 1 2 2 1 1 1

4EOZ

GM20641-SA1 1 1 1 1 1 1 1 1 1

TP-6138 5/02

3

Group 1: Crankcase

6138_1

Quantity

Part Variation No.

Item Number Description 1

1 GM24007 Crankcase Assembly 1

2 GM23884 Stud, Cylinder Block 2

3 GM23885 Stud, Cylinder Block 2

4 GM23886 Stud, Crankcase 4

5 GM23870 Switch, Oil Pressure 1

7 GM23934 Gasket, Crankcase 1

10 GM23955 O-ring, 99 x 3 mm 1

11 GM23927 Housing, Main Bearing 1

12 GM23965 Retainer, Ring 1

13 GM23973 Seal, Oil, 60 x 80 x 8 mm 1

14 # Nut, Hex Head, M8 4

15 # Washer, Tooth, 18 mm 4

16 GM23925 Pump Assembly, Oil 1

17 GM23937 Gasket, Oil Pump 1

18 # Washer, Split, 6 mm ID 3

19 # Screw , Hex Head Cap, M6 x 20 1

20 # Screw , Hex Head Cap, M6 x 30 2

# Common hardware; procure locally .

TP-6138 5/02

4

Group 2: Crankshaft and Piston

6138_2

TP-6138 5/02

5

Group 2: Crankshaft and Piston

Quantity

Part Variation No.

Item Number Description 1 2

1 GM24009 Crankshaft Assembly 1 1

3 GM23954 O-ring, 32 x 2 mm 1 1

4 GM23893 Ring, Angle 1 1

5 GM23946 Washer , Spring, 52 x 36 x 1.2 mm 2 2

6 GM23891 Nut, Flywheel 1 1

7 GM23879 Gear, Timing Crankshaft 1 1

8 GM23942 Bushing, Main (Standard) 1 1

8 GM23943 Bushing, Main (0.25 mm Undersize) 1 1

8 GM23944 Bushing, Main (0.50 mm Undersize) 1 1

9 GM24000 Bearing (Standard) 1 1

9 GM24001 Bearing (0.25 mm Undersize) 1 1

9 GM24002 Bearing (0.50 mm Undersize) 1 1

10 GM23975 Key,6x4x12mm 2 2

11 GM23945 Bearing, Main 1 1

12 GM23906 Governor Assembly (RPM=3000E) 1

12 GM23907 Governor Assembly (RPM=3000) 1

12 GM23908 Governor Assembly (RPM=3600E) 1

13 GM23974 Pin, 4 x 27.8 mm 1 1

15 GM24010 Piston Assembly 1 1

16 GM24006 Set, Piston Ring 1 1

17 GM23983 Clip, Piston Pin 2 2

18 GM23874 Pin, Piston 1 1

19 GM23926 Rod Assembly, Connecting 1 1

20 GM23883 Bolt, Connecting Rod 2 2

21 GM23890 Nut, Collar 2 2

22 GM23882 Bushing, Connecting Rod 1 1

24 # Plug, 22 mm 4 4

25 GM23997 Connector, Water Tube 2 2

26 GM23953 O-ring, 10 x 2.2 mm 2 2

27 GM24011 Cylinder Assembly 1 1

# Common hardware; procure locally .

TP-6138 5/02

6

Group 3: Cylinder Head

6138_3

TP-6138 5/02

7

Group 3: Cylinder Head

Quantity

Part Variation No.

Item Number Description 1

1 GM24012 Head Assembly, Cylinder 1

2 GM23921 Valve, Breather 1

3 GM23941 Gasket, Cylinder Head 1

4 GM23878 Valve, Intake 1

5 GM23990 Washer 2

6 GM23876 Guide, V alve 2

7 GM23964 Guide, Oil Seal 2

8 GM23947 Spring, Valve 1

9 GM23895 Retainer , V alve Spring 2

10 GM24005 Valve, Cotter 2

11 GM23877 Valve, Exhaust 1

12 GM23894 Ring 1

14 GM23911 Rotocap, Valve 1

15 GM23948 Spring, V alve 1

16 GM23951 Spring, Retainer 1

17 GM23967 Stud, M5 x 10 2

18 # Washer, 5 mm ID 2

19 # Nut, Hex Head, M5 2

20 GM23872 Shaft, Rocker Arm 1

21 GM23919 Arm Assembly, Rocker 1

22 GM23918 Arm Assembly, Rocker 1

23 GM23889 Screw, Adjusting 2

24 # Nut, Hex Head, M7

25 GM23902 Injector, Fuel 1

26 GM23962 Washer 1

27 GM23903 Nozzle, Fuel Injector 1

28 GM23904 Seat, Spring 1

29 GM23905 Spring, Nozzle 1

30 GM23991 Flange, Injector 1

31 GM23972 Stud, M6 x 50 1

32 GM23971 Stud, M6 x 45 1

33 # Washer, Split, 6 mm ID 2

34 # Nut, Hex Head, M6 2

35 GM23987 Tube, Push Rod 1

36 GM23956 O-ring, 24 x 3.5 mm 1

37 # Plug, 22 mm 2

38 # Plug, 18 mm 1

39 GM23932 Gasket, Rocker Cover 1

40 GM23920 Cover, Rocker 1

41 # Washer, 5 mm ID 2

42 GM23989 Bracket, Lifting 1

44 GM23890 Nut, Collar 6

45 # Plug, 18 mm 1

47 GM23914 Switch, Temperature Alarm 1

48 GM23981 Washer , Copper, 14 mm ID 1

49 # Screw , Hex Head Cap, M8 x 20 2

50 # Washer, Split, 8 mm ID 2

52 GM23931 Gasket 2

53 GM23912 Thermostat 1

54 GM24140 Cover, Thermostat 1

# Common hardware; procure locally .

TP-6138 5/02

8

Group 4: Gear Timing and Cover

6138_4

TP-6138 5/02

9

Group 4: Gear Timing and Cover

Quantity

Part Variation No.

Item Number Description 1

1 GM23923 Cover, Timing Gear 1

3 GM23933 Gasket, Cover 1

4 GM23976 Pin, 10 x 16 mm 2

8# Washer, Split, 5 mm ID 1

9 GM23887 Screw, Hex Head 1

10 GM23958 Gasket 1

11 GM24003 Cap, Oil Filler 1

12 GM23929 Dipstick 1

13 GM23968 Stud, M8 x 20 2

14 GM24013 Screen Assembly, Oil Filter 1

17 GM23938 Gasket, Oil Filter 1

18 GM23977 Washer , Copper, 6 mm ID 2

19 # Screw, Hex Head, M6 x 20 2

20 # Screw, Hex Head Cap, M8 x 70 2

21 GM24004 Handle 1

24 GM24008 Primer Assembly 1

25 # Screw , Hex Head Cap, M8 x 80 3

26 GM23993 Shim, Adjusting, 0.2 mm 1

26 GM23994 Shim, Adjusting, 0.5 mm 1

26 GM23995 Shim, Adjusting, 0.4 mm 1

26 GM23996 Shim, Adjusting, 1.0 mm 1

27 GM23939 Gasket 1

28 GM23901 Roller , Tappet 1

29 GM23896 Pump, Fuel Injection 1

30 # Washer, Split, 8 mm ID 1

31 # Nut, Hex Head, M8 2

32 GM23897 Washer 1

33 GM23900 Valve 1

34 GM23898 Spring, V alve 1

35 GM23899 Plunger , Fuel 1

36 GM23875 Push Rod 2

37 GM23957 O-ring, 32 x 3 mm 1

38 # Screw, Hex Head Cap, M5 x 30 2

39 GM23922 Release, Compression 1

40 GM23936 Gasket, Plate, 0.3 mm 1

40 GM23940 Gasket, Plate, 0.4 mm 1

42 GM23966 Bearing, Grooved Ball 1

43 GM23960 O-ring, 32.7 x 1.3 mm 1

44 GM23873 Bolt 1

45 GM23924 Camshaft 1

46 GM23880 Gear 1

47 GM23975 Key,6x4x12mm 1

53 GM23917 Cover 1

55 GM23961 O-ring, 57 x 2.5 mm 1

56 # Washer, Split, 6 mm ID 2

57 # Screw , Hex Head, M6 x 16 2

58 GM23930 Gasket, Plate 1

59 GM23985 Cover 1

60 GM23979 Washer , Copper, 5 mm ID 2

61 # Screw, Hex Head, M5 x 16 2

62 GM24511 Ring, snap 1

# Common hardware; procure locally .

TP-6138 5/02

10

Group 5: Speed Control Shaft

6138_5

Quantity

Part Variation No.

Item Number Description 1

1 GM23949 Spring, Torsion Return 1

2 GM23916 Arm, Governor 1

3 GM23888 Screw, Adjustment 1

4 GM23992 Tab, Locking 1

5# Nut, Hex Head, M6 1

6 GM23952 Retainer 1

7 GM23871 Shaft, Speed Control 1

8 GM23953 O-ring, 10 x 2.2 mm 1

9 GM23950 Spring, Torsion Return 1

10 GM23986 Plate, Control 1

11 GM23984 Lever 1

12 # Washer, Tooth, 8 mm 1

13 # Nut, Hex Head, M8 1

14 GM23913 Bolt 1

# Common hardware; procure locally .

TP-6138 5/02

11

Group 6: Fuel Lines

6138_6

Quantity

Part Variation No.

Item Number Description 1

1 GM23999 Line, Return Fuel 1

2 GM23982 Bolt, Banjo Union 2

3 GM23959 W asher , Copper, 8 mm ID 1

4 GM23978 Washer , Copper, 8 mm ID 3

5 GM23892 Connector 1

6 GM23980 Washer , Copper, 12 mm ID 4

7 GM23988 Clamp, Fuel Line 1

8 GM23998 Pipe, Fuel Injector 1

9 GM24072 Solenoid, Shutoff 1

10 GM24099 Bolt, Banjo Union 1

11 # Eye, Fuel Supply Line 1

# Common hardware; procure locally .

X-6288-1

TP-6138 5/02

12

Group 7: Flywheel

6138_7

Quantity

Part Variation No.

Item Number Description 1

1 GM23928 Flywheel 1

2 GM23881 Gear 1

# Common hardware; procure locally .

TP-6138 5/02

13

Group 8: S tarter Motor

6138_8

Quantity

Part Variation No.

Item Number Description 1

1 GM23910 Starter Assembly, 12 Volt 1

2 # Screw, Hex Head Cap, M8 x 20 4

3 GM24083 Plate, Connecting 1

4 GM24109 Spacer 3

5# Washer, Tooth, 8 mm ID 4

6 GM24097 Housing, Flywheel 1

7 GM23909 Bushing 1

8 GM23969 Stud, M10 x 25 3

9 GM23970 Stud, M10 x 25 1

10 # Washer, Spring, 10 mm ID 4

11 # Nut, Hex Head, M10 4

# Common hardware; procure locally .

TP-6138 5/02

14

Group 9: Exhaust System

6138_9

Quantity

Part Variation No.

Item Number Description 1

1 GM24074 T ube, Mixing 1

2 # W asher, Plain, 8 mm ID 2

3 # W asher, Split, 8 mm ID 2

4# Screw , Hex Head Cap, M8 x 55 2

5 GM24021 Clamp, Hose 8

6 GM24120 Hose 1

7 GM24103 Nipple 1

8 GM24512 Hose 1

9 GM24119 Adapter, Rubber Tube 1

10 GM24063 Hose 1

11 GM24051 Switch, Temperature Alarm 1

12 # Washer, Tooth, 3 mm ID 2

13 # Screw, Round Phillips Head, M3 X 6 1

14 GM23935 Gasket 1

15 # Plug, Cap, 1/8 1

16 GM24124 Hose 1

# Common hardware; procure locally .

TP-6138 5/02

15

Group 10: Oil Cooler and Lines

6138_10

Quantity

Part Variation No.

Item Number Description 1

1 GM24114 Element, Oil Cooler 1

2 GM24112 Elbow 2

3 # W asher, Tooth, 6 mm ID 6

4# Screw , Hex Head Cap, M6 x 30 6

5 GM24021 Clamp, Hose 8

6 GM24121 Hose 1

7 GM24104 T ube 1

8 GM24122 Hose 1

9 GM24118 Hose 1

10 GM24116 Hose 1

11 GM24027 Adapter , Rubber Hose 3

12 GM24102 Tube 1

# Common hardware; procure locally .

TP-6138 5/02

16

Group 11: Seawater Pump

6138_11

Quantity

Part Variation No.

Item Number Description 1

1 GM24052 Pump Assembly, Seawater 1

2 GM24106 Shaft, Seawater Pump 1

3 GM24032 Seal 1

4 GM24053 Housing, Seawater Pump 1

5# Screw , Hex Head Cap, M5 x 40 3

6 GM24031 O-ring 1

7 GM20852 Impeller 1

8 GM24054 Cover, Seawater Pump 1

9 # Screw, Hex Head, M4 x 8 4

# Common hardware; procure locally .

Note: Item 1, Seawater 

pump does not include items 

2 and 5.

TP-6138 5/02

17

Group 12: Oil Draining Lines

6138_12

Quantity

Part Variation No.

Item Number Description 1

1 GM24143 Bushing, Reducer 1

2 GM23980 W asher , Copper, 12 mm ID 2

3 GM24142 Eye, Banjo Union 1

4 GM24141 Bolt, Banjo Union 1

5 GM24020 Clamp, Hose 2

6 GM24117 Hose, Oil Draining 1

7 GM24111 Adapter, Rubber Hose 1

8 GM24113 Plug, M8 x 10 1

9 GM24513 Clip, hose 1

# Common hardware; procure locally .

TP-6138 5/02

18

Group 13: Fuel Filter and Pump

6138_13

Quantity

Part Variation No.

Item Number Description 1

1 GM24125 Hose, Fuel 1

2 GM24020 Clamp, Hose 8

3 GM20850 Filter , Fuel 1

4 GM24126 Hose, Fuel Supply 2

5 GM24055 Pump, Fuel 1

6# Washer, Plain, 6 mm ID 2

7 # W asher, Split, 6 mm ID 2

8 # Screw, Hex Head, M6 x 16 2

9 GM24127 Hose, Fuel Return 1

10 GM24025 Adapter, Fuel Hose 2

11 GM24024 Connector, Fuel Hose 2

12 # Plug, 1/4 NPT 2

# Common hardware; procure locally .

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